Plant Head - Manufacturing of Silo & Tanks

Job Description

Plant Accountability - Accountable for entire operations of SILO, TANK processes in the plant. - Accountable for heading 97 Staff & 700 Workers and managing the areas as Production, Engineering, PPC, Stores, QA, Maintenance & Utilities, Administration, Accounts & Logistics. - Accountable for achievement of MFO Targets in terms of Safety, Quality, Cost, Delivery and Morale. Production Planning - Planning day-to-day activities, production schedules, implementing quality tools and allocating work for achieving of monthly production targets. - Strategic planning for capacity enhancements of complete manufacturing operations for more than ___ crores of turnover this year & ensuring smooth functioning of the plant to achieve the set targets as per quality standards. - Appraising the prevalent production systems/ processes, identifying loopholes, if any and undertaking result-oriented measures for alleviating them. - Leading a team of Engineers, Science Graduates and contract workman's for achieving the monthly business plan targets of production. - Set up goals for cost reductions & savings. Plant Operations - Getting maximum production with the required yield as well as Optimizing man power & machinery utilization to achieve pre-set targets compliance with the quality & time. - Monitoring daily production & consumption of inventory, coordinating with material section for raw material planning based on consumption and overall logistics planning. - Focus on Material Balancing, Costing, Loss and recovery calculations. - Conceptualizing & implementing projects, annual improvement plans for production reengineering, technology absorption projects for expansion and new products. - Identifying areas of obstruction/ breakdowns and take steps to rectify the trouble shooting operational problems and continuously monitoring the plant performance. - Daily Review meeting with all concerned HODs for last day's failure analysis along with corrective action plan & current day's & future targets analysis. - Minimizing performance bottlenecks for achieving high productivity with maximization of material & machine. - Coordinating material spare parts planning related activities encompassing identification of vendors, requirement of specification and offer evaluation. -- - Planning and executing capital procurement. - Monitoring of consumables in terms of Quality, Consumption and Inventory management of the same. - Set up standard operating procedure for individual process from Raw material input through gate to FG out from gate. - Set up and monitor daily, weekly and monthly production target and plan for raw material, consumable. Follow up and modify the entire plan as per customer need. Quality Assurance - Ensuring the Quality check of incoming raw material. - Ensure stringent sample quality checks at each stage of production process on all critical product parameters. - Analysis of quality related problems based on the data, identification of bottlenecks and key issues. Modification of the process route and equipment for - the better productivity and quality. - Quality defect analysis by seven quality tools and six sigma method. - Ensuring continual improvement for productivity, quality & process as a core member of the team. - Training and guiding teams on towards identifying factors critical to quality, reducing process variation, improving capabilities & increasing stability. Process Improvements - Ensure robust process and expansion of plant. - Ensure Process Improvement to make uninterrupted quality product. - Introduce Mechanical and Electrical Poka yoke to ensure Quality products. - Reduction in cycle times to meet increasing customer demands. - Study of process to reduce in house rejection. - Focus on New product development. Manpower Management - Identifying the manpower requirement on daily basis based on the production plan. - Plan and monitor deployment of Workers as per the work plan. - Monitoring the performance level of the staff & workers for ensuring accomplishment of the target. - Organizing regular periodic meetings & trainings for staff & engineers for discussing current work issues and devising solutions for enhanced operations. - Imparting floor training to operating people for enhancing their knowledge and improving the efficiency. Inventory Management - Ensure inventory in Receipt store and FGS. - Control of Inventory by monitoring Min - Max level, Inventory Turn Ratio and dead inventory. - Ensure tool and maintenance store inventory control and availability of spares as per defined Min - Max level. - Ensure quarterly inventory audit . Justification and action plan for variance. Maintenance Perspective - Ensure availability of machine whenever there is production. - Monitoring Breakdown, Preventive, Predictive & Proactive maintenance. - Ensure 5S Activities, Implementation of Kaizens - (Reduce cycle time, Quality Maintenance & Energy Saving). - Documentation for getting TS 16947 & ISO 14001 certificate. - Ensure carry out in house low cost automation projects to meet customer expectation. - Involving Maintenance personnel while deciding new machines to ensure machines spares as per standards to reduce maintenance time and cost. - Ensure Automation as per specific requirement of production. - Energy conservation activities initiation and monitoring. Business Planning & Controlling P&L Account - Preparation and execution of yearly plant budget (revenue and Capex) - Effective cost control with optimization of resources. - Control on cash flow, Inventory and working capital. Risk Management - Risk assessment and contingency planning of all kind of operational risks associated with business. - Risk cards to be made and to be reviewed monthly. Administrative & Safety Perspective - Effective contractor management and Implementation of contractor performance score card. - Responsible for Effective Trade Union management. - Manpower planning, recruitment, productivity control, and KRA implementation, Implementation of performance driven culture, IDP, On-the-job training for accomplishing greater operational effectiveness efficiency. - Managing and controlling all aspects of various statutory compliances along with co-coordination with local regulatory authorities. - Ensuring high-quality house-keeping and adherence to other shop floor compliances. - Responsible for overall safety of employees and plant machinery as factory manager. To take initiatives and introduce robust system of safety, Health and Environment management. People Perspective - Motivate the team for high morale and help them in grooming their talents. - Employee engagement activities to be done through adequate communication and celebrating the achievements. - Identifying the training needs and help them in closing the gaps. - Handling employee grievances and resolving them amicably. Development Perspective - Establish a system of reports and communications for all information and for feedback to the entire plant functions. - Develop ongoing liaison with key opinion leaders, attending & updating various conferences and seminars for team & self development, touching base with other organizations of same industry to ensure that significant developments are identified & applied. - Ensure that the systems are in place whereby whole plant functional teams are aware with the SOPs and the code of conduct to be followed. - Responsible for performance appraisal of all plant employees and for providing training and development opportunities including succession planning. - Ensure effective functioning across the cross-functional teams. MIS Reports - Responsible for providing MIS charts Power point presentation comparison sheets for Target Planned Vs Achieved defects reported inventory WIP finished , Corrective and Preventive Action (CAPA) taken to management on daily weekly monthly basis etc.